TECHNICAL GUIDE - Legrand

TECHNICAL GUIDE
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TECHNICAL
GUIDE
Power
CABLOFIL ®
the global solution
High-quality steel wire cable supports
Unique safety edge
Fast install system
Data
High level mechanical and electrical
performance
Control Process
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Applications - Sustainable development ............04
Mechanical resistance ............06
Metals and surface treatments ............08
Food industry safety ............10
Electromagnetic compatibility ............12
Electrical continuity – Earth network ............14
Power cables ............16
Efficient data cabling ............18
Fibre optic cables ............19
Copper data cables ............20
Standards and directives ............22
Fire resistance ............24
Fire protection: EZ-Path ® ............26
References ............32
Decision-making software ............33
Specifications ............34
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Applications
BUILDING SERVICES
INFRASTRUCTURE
HEAVY INDUSTRY
PROCESSING INDUSTRIES
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Sustainable development
Sustainable development, once the preserve of
legislators and governments, has become a fact
of life for all stakeholders within society. Today's
project managers, whether in an industrial, services
or infrastructure context, need to respect the
environment and consider the human impact of their
actions.
CABLOFIL ® is fully aware of these issues and behaves
responsibly across all its sites and organisational
structures. The company also extends this approach
to its partners, with a view to developing a lasting
commitment in this area.
SITE MANAGEMENT: ISO 14001
environmental management at sites
PRODUCT DESIGN
Health and environment
Directive
IMPROVED ENERGY EFFICIENCY
- ISO 9001
on-site
cable ventilation
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Mechanical resistance
First and foremost, a cable tray must act as an effective, resistant and durable support for
cables.
The mechanical performance of all products and accessories is tested against the very
demanding requirements imposed by the international standard IEC 61537.
SAFE WORKING LOADS FOR CABLE
TRAYS
1/100 th
th
Load (kg/m)
140.0
120.0
100.0
80.0
60.0
40.0
20.0
CF54 PG, EZ, GC
0.0
1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500
Span (mm)
th -
th .
CF 54/50 to 100
CF 54/150
CF 54/200
CF 54/300
CF 54/400 to 500
CF 54/600
LOAD TESTS: TEST CONFIGURATION
ACCORDING TO STANDARD IEC 61537
th
th
1/200 th
SAFETY
becomes like a hammock.
SAFE WORKING LOAD FOR SUPPORTS
Calculation rules:
Total F = F1 + F2 + F3 < permissible hanger load
Total T = F1.d1 + F3.d3 – F2.d2 < permissible hanger torque
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P2000
> Exclusive to CABLOFIL ® : 25% savings with the P2000 (span of 2 m at full capacity).
1.5 m span.
0.5 m 0.5 m
1.5 m 2 m 2 m
2 m
0.4 m.
POSITIONING OF THE COUPLERS (general scenario applicable to all spans)
Optimum Possible
L/5 L/2
1/5 th
POSITIONING OF THE SUPPORTS
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Metals and surface treatments
Uncontrolled corrosion is a recurrent problem with all applications
involving metals, it may lead to a reduction in the
performance and lifetime of the installation.
Cable trays are mainly exposed to atmospheric corrosion.
The environment in which the cable trays are installed
is therefore the main criteria in the choice of surface
treatment, or type of steel.
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GALVANIC CORROSION
Partner metal
Corrosion is
electrochemical
Stainless steel 0
phenomenon
Nickel 180
Copper 320 140 0
Brass 400 220 80 0
potential between
Tin 550 370 230 150 0
Steel 750 570 430 350 200 0
or between a metal
Aluminium 840 660 520 440 290 90 0
Chromium 950 770 630 550 400 200 110 0
Zinc 1150 970 830 750 600 400 310 200 0
Differences in potential are expressed in millivolts.
Beneath the red line, the metal involved is attacked.
It is important to
Metal involved
Stainless steel
Nickel
Copper
Brass
Tin
Steel
Aluminium
Chromium
Zinc
COATED STEELS
Recommended
Possible
GS EZ GC DC 304L 316L
normal environment
urban environment
Halogen environment
PG/GS: Continuous galvanisation before
PG
manufacture using the Sendzimir process
GS
continuous immersion on the steel sheets or wires. The
EZ
Electrogalvanising after manufacture
> Ongoing protection
Zinc hydroxide
PG
Wire cable trays
EZ/PG
GC
304L
316L
Accessories
EZ/GS
GC/DC
304L & 316L
316L
Zn anod
Fe cathod
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GC
Hot dipped galvanised after manufacture
DC Geomet ®
Geomet ®
Epoxy
PG
Carbon
steel
EZ
GC
1500
1400
1200
1000
800
600
400
300
200
100
304L
Stainless
steel
304L
Pickled
& passivated
316L
Untreated
Untreated
x 4 x 5
316L
Pickled
& passivated
STAINLESS STEELS
coating. CABLOFIL uses two austenitic stainless
304L Stainless steel 304 L
AISI 304L – X2CrNi18.09 – 1.4307
Stainless steel 316 L
316L
AISI 316L – X2CrNiMo17.12.2 – 1.4404
316L is able to resist intergranular corrosion. This
> Decontamination of stainless steels
Pickling in greasing eliminates
pollutants.
Passivation
2
processes.
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Food industry safety
Safety in the food processing industry is critical. Production lines must be kept clean. Even
the smallest risk of contamination can result in operational losses and have dramatic
repercussions for public health and a company's image.
HACCP DIRECTIVES
COMPLETE FOOD SAFETY
inspections.
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AN ADAPTABLE SYSTEM
PREMIUM SERVICE
DURABILITY GUARANTEED
CABLOFIL has two low-carbon stainless steel ranges
resistant to the corrosion
processes or agents. As
to last longer.
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Electromagnetic compatibility
Understanding EMC involves the analysis of electromagnetic pollution between a source of
disturbance and its victim.
PHENOMENON
Metallic cable trays with excellent electrical
continuity which are integrated into an installation's
equipotential earthing network reduce the effects
of coupling and therefore improve an electrical
installation's EMC.
THE GOLDEN RULES!
Remember the
separate.*
at right angles.
Source Coupling Victim
Make sure electrical
THE CABLOFIL ® SOLUTION
to the earthing
please contact our technical support service.
EMC TESTS
electrical installation.
EXCELLENT
Excellent EMC performance
Cable arrangement can be inspected visually.
POSSIBLE
Similar performance to wire cable trays,
but limited scope for visual inspection
CAUTION
Do not mix power and data cables in the same
compartment
When integrated into the earthing network, CABLOFIL's metallic cable trays help electrical installations
achieve excellent EMC levels.
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CONFIGURATION OF THE 1 ST TEST:
Data cable in an external electromagnetic field
Cable with no metal tray (for
comparison) Cable in CABLOFIL ® Cable in perforated sheet
CONFIGURATION OF THE 2 ND TEST:
Data cable alongside a power cable
Generation of electromagnetic interference by
injecting current into the power cable
Cable in CABLOFIL ® with cover
Cable in raceway with cover
Measurement of the interference generated in the data cable
A comparison of the impact of 3 of the 118 configurations
Interference within
the cable in dBμV
> Results and interpretations
These tests show that there is no significant difference
in "Faraday cage" effect offered by wire mesh or
perforated cable tray.
Frequency
> Results and interpretations
This second test configuration confirms that metal
cable trays reduce interference (wire mesh or perforated
tray).
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Electrical continuity
Fundamental to providing safety to people and property, electrical continuity also plays an
essential role in the EMC performance of an electrical installation.
DEFINITION
THE IMPORTANCE OF HAVING EXCELLENT
ELECTRICAL CONTINUITY
Guarantee the safety of people and property:
avoiding any risk of electrocution.
No couplers = DANGER
Couplers = SAFE
TESTED FOR ELECTRICAL CONTINUITY
CABLOFIL trays
Tests show that CABLOFIL more than meets the
5 m /m.
CABLOFIL couplers
. The test involves running an
Test configuration

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Earth network
Earthing (1) an installation is vital for the safety of people and property. Furthermore it plays
an active role in EMC.
DEFINITION
metallic
potential.
Protective
conductor
Earth
BENEFITS OF AN EQUIPOTENTIAL
EARTHING NETWORK
-
level
CABLOFIL ® INTEGRATED IN THE EARTH
NETWORK
Role of the protective conductor: The protective
Earth conductor
Earth rod
DEDICATED ACCESSORIES
Grifequip:
2
Grifequip 2:
35 mm 2
Bimetal terminal: Bimetal
2
Terminal support + bimetal
terminal: For earthing in
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Power cables
Electricity transfer generates energy losses in the form of heat. By improving the heat dissipation
of power cables, substantial savings can be made. The open structure of CABLOFIL ®
maximises ventilation and therefore reduces installation and operational costs.
ASSESSMENT
ρ ρ x
L
S
2
SOLUTIONS
temperature.
ENERGY SAVING EVALUATIONS
120%
100%
80%
60%
40%
100 %
96 %
91 %
78 %
77 %
Useful energy
Lost energy
63 %
63 %
20%
0%
-20%
-40%
-60%
Cablofil
- 4 %
Perf. tray
- 10 %
Cablofil +
cover
- 22 % - 23 %
Perf. tray +
Plastic
cover
trunking
- 37 % - 37 %
Metallic
conduit
Metallic
trunking
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In spite of the electrical protection equipment of the network, energy transfer will always
present risks to people and property. CABLOFIL ® is able to manage these risks with its
high performance cable supports.
SHORT CIRCUITS
SHORT CIRCUIT TESTS
repulsion between the power cables.
coupling 1/5 th
using cleats.
Insulating
cover
Copper or
aluminium core
Sheath
During test
CONCLUSION
Class
Intensity
Class 1 Class 2
70 kA
100 kA
130 kA
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Efficient DATA cabling
In order to manage data installations and master their complexity, it is necessary to have
a high performance cabling system which has the capacity to evolve.
With the relevant standards in mind, CABLOFIL ® helps design, organise and arrange a variety
of cabling systems, whilst also ensuring system safety.
DATA SECURITY AND INTEGRITY
MAINTAINING AND DEVELOPING THE
INSTALLATION
is able
COST MANAGEMENT
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Fibre optic data cables
The development of fibre optics is a direct result of the growing demand for fast data
transmission between different terminals. Given its immunity to electromagnetic interference
and its characteristics in terms of signal transmission, fibre optics are the ideal support for
high-speed data transmission.
DEFINITION
.
TYPES OF FIBRE OPTIC
> Single-mode fibre optic
Categories
Diameter
Throughput
Bandwidth
> Multi-mode, step-index fibre optic
> Multi-mode, graded-index fibre optic
OS1
9/125 μm
≥ 10 Gbits/s
≥ 25 Gbits.km
Categories OM1 OM2 OM3
Diameter 62.5/125 μm 62.5/125 μm, 50/125 μm 50/125 μm
Throughput 100 Mbits/s to 1Gbit/s ≤ 1 Gbit/s ≤ 10 Gbits/s
Bandwidth for 850 nm 200 MHz.km 500 MHz.km 1500 MHz.km
Bandwidth for 1350 nm 500 MHz.km 500 MHz.km 500 MHz.km
COMPONENTS OF A FIBRE OPTIC CABLE
along the optical core
-
-
Protective
covering
Optical
core
Primary cladding
Optical cladding
ensures the optical waves
remain in the core. The
against the barriers Light ray
.
ADVANTAGES
THE CABLOFIL ® SOLUTION
CF54/100
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Copper data cables
The development of communications cable technology is rapidly changing and the use of
high-speed networks is growing exponentially. CABLOFIL ® has become accepted as the ideal
support for copper communication cables (coaxial cables and twisted pairs).
NEW STANDARDS FOR NEW PERFOR-
MANCE
The category
6 approval.
The class
a combination involving more than one component
Category Class Throughput Frequency
Cat. 5 D ≤ 100 Mbits/s 100 Mhz
Cat. 5e D ≤ 100 Mbits/s 155 Mhz
Cat. 6 E ≤ 1 Gbit/s 250 Mhz
Cat. 6a Ea ≤ 10 Gbits/s 500 Mhz
Cat. 7 F ≤ 10 Gbits/s 600 Mhz
Cat. 7a Fa ≤ 10 Gbits/s 1000 Mhz
COAXIAL CABLE
level.
TWISTED PAIR
U/UTP
the cheapest.
F/UTP
S/FTP or S-STP
Protective sheath
Metal braid
Dielectric
Copper core
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RELIABILITY AND DURABILITY
The two major considerations for the network infrastructures are the reliability and durability
of the installation. In order to measure the positive contribution made by CABLOFIL ® , even when
overloaded with cables, a series of independent tests were carried out.
> Independent tests
> Measurements
parison
purposes is Return Loss.
to return to its source.
> Test for reliability under load
Results:
base.
CABLOFIL ®
not loaded
Flat surface not
loaded
CABLOFIL ®
under load
Flat surface
under load
> Test of durability under load
Results:
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Standards and directives
The manufacture and use of cable trays are subject to strict and precise regulations. CABLOFIL ®
gives an update on the applicable texts and ensures its products are compliant.
Difference between a directive and a
standard
DIRECTIVES
> The EMC Directive 89/336/EEC, repealed
by the 2004/108/EC Directive
> The "LVD" Directive
> The "CE Marking" Directive
THE RoHS DIRECTIVE
st
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STANDARDS
The IEC 61 537 standard, "Cable tray systems and cable ladder systems for electrotechnical
installations", defines the characteristics of cable trays.
> The IEC 61 537 standard
CE MARKING
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CERTIFICATIONS FOR CABLOFIL ®
ISO 9001
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Fire resistance
Safety is a major concern for everyone, but can only be achieved with knowledge of how electrical
equipment behaves in the event of a fire. CABLOFIL ® has been successfully tested and
proven to meet all fire-safety requirements.
STANDARD DIN 4102-12
Period
Certification
> 30 minutes E 30
> 60 minutes E 60
> 90 minutes E 90
RECOGNISED INDEPENDENT
LABORATORIES
TEST CONFIGURATION
with a
Cables are
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CABLOFIL ® is certified to E90 for a number of configurations that meet the requirements of data
transfer facilities designed to ensure the protection of property and people in the event of a fire.
Below are 9 representative samples of the more than 20 configurations tested.
Light duty
TF8
TF8
TF8
CF54/50
CF54/50
UC 50
CF30/100
CAT 30
R21S
CM50XL
1200 mm 2 kg/m 1200 mm 5 kg/m 1200 mm 5 kg/m
CF54/50
CF54/50
CF30/100
Medium duty
CSNC 150300
TF8
TF8
20 kg/m
CF54/400
CF54/100
CSN150
TF10
TF8
CF54/100200
CF30/200
CF54/300
20 kg/m 1 kg/m
5 kg/m 5 kg/m
CF54/50
CF30/200
CF54/150
CSN200
CF54/300
CSN400
TF12
R41S
1250 mm 10 kg/m 1200 mm
1 kg/m
to 20 kg/m
1250 mm 10 kg/m
CF54/100200
CF54/50400
Heavy duty
CF30/200
CF54/100300
CF54/300
TF8/10/12
CF105/400
10 kg/m
20 kg/m
PFREDF
CU500
CF54/300
CF54/150
C41S200
TF8/10/12
P41S 300 to 1000
TF12
CF54/400
CF54/400
C41S 500
P41S 300 to 1000
C41S 500
CU500
CF105/400
20 kg/m
EDF600
C41S 400
CF54/400
CF54/400
C41S 500
CU500
C41S 500
1200 mm
1 kg/m
to 20 kg/m
1250 mm 10 kg/m 1250 mm 10 kg/m
CF54/300
CF105/400
CF54/150400
CF54/100400
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Fire protection
Preventing a fire from spreading not only saves lives but can significantly reduce further
damage to property.
Fire prevention is a critical factor in an electrical installation. Specialist designers have the
task of making these installations safe and flexible whilst respecting the rules relating to
passive protection.
FIRE PROTECTION RULES
Compartmentation of
different zones
Stop fire from spreading
Restore the integrity of
compartments
-
-
the original wall.
SOLUTIONS
> Conventional firestops
> EZ-Path firestop device
Non-compliant
Compliant
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EZ-Path ®
The relentless development of electrical and datacom installations demands readily adaptable
firestop solutions. EZ-Path ® , the firestop solution from CABLOFIL ® , is able to satisfy both
the requirements associated with modern buildings and those imposed by fire protection
regulations.
GUARANTEED FIRE PROTECTION
PROTECTION OF PEOPLE
MAINTENANCE AND DEVELOPMENT
As soon as EZ-Path
COMPLIANCE GUARANTEED
ADDITIONAL FEATURES AND BENEFITS
rate to 0.5 m 3
vex shape
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A FAST AND FLEXIBLE SYSTEM
COST MANAGEMENT
3,5
3
2,5
Solution cost
2
1,5
1
0,5
0
initial installation 1st Modification 2nd Modification 3rd Modification 4th Modification
Mortar Intumescent foam EZ-Path
EZ-Path ®
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STANDARDS AND CERTIFICATIONS
> Standard applications
Definition
Aim
Procedure
Example:
> Results of each standard
Zone Standard Class
Europe EN1366-3 EI120
United Kingdom BS 476: Part 20 EI60
Germany DIN 4102-9 S90 or EI90
Russia NPB ( ) 237-97 IET90 or EI90
America ASTM E814 (UL1479) F rating – 4 h or E240
> Specific marine applications
Metallic partitions in the WFRC test wall
Aim
a ship.
Procedure
Results
> Noise barrier and leakage rate
The STC rating
The L Rating
The EQLA
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Implementing Ez-Path ®
make an opening.
HORIZONTAL INSTALLATION
Module 22 Cat. No. Code Kit
DRY PARTITIONS & CONCRETE WALL
Framework
Ø Coring
Cables
in place
EZDP 22
mm
mm
23 31
250518
45x45 mm
Ø 52 mm
x
Number of
Module 33 Installation Plates* and accessories Code
modules
267
DRY PARTITIONS & CONCRETE WALL
Framework
Ø Coring
1 EZP133R 250210 80x80 mm
Ø 102 mm
1 EZP133CW 250240 80x80 mm
Ø 102 mm
x
1 EZP133W 250110 80x80 mm x
Cables
in place
75
2 EZP233W 250120 80x155 mm x
75
EZD 33
mm
mm
56 69
3 EZP333W 250130 80x230 mm x
4 EZP433W 250140 80x305 mm x
7 EZP733W 250170 80x535 mm x
1 EZD33E 250078
1 RCM33E 250206
Module 44
Number
Installation Plates* Code
of modules
DRY PARTITIONS & CONCRETE WALL
Framework
Ø Coring
Cables
in place
118
353
1 EZP144W 250230 120x105 mm
x
Ø 152 mm
102
EZD 44
mm
mm
78 97
120x105 mm
1 to 5 EZP544W 250250
120x206 mm
120x308 mm
120x410 mm
120x511 mm
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MAXIMUM MODULE CAPACITY
Modules
VERTICAL INSTALLATION
Ø of cables (mm)
3.5 4.5 5.5 6 7.5 8 10 14 16 18 21 22 24 26 29 32 38 48 60 70 75
Maximum number of cables
EZDP22 58 30 20 17 11 10 6 3
EZD33 280 140 99 75 51 45 29 12 10 6 5 5 4 3 1 1
EZD44 654 331 224 178 127 107 73 33 23 19 13 11 9 7 6 4 3 2 1 1 1
Number of
Module Code Installation Plates* Code
modules
FLOOR
Framework - Ø Coring
EZD 33 250018 1 EZP133K 250220
80x80 mm
Ø 102 mm
Number of
Module Code Installation Plates* Code
modules
EZD 44 250058 1 EZP144F 250260
FLOOR
Framework - Ø Coring
120x105 mm
Ø 152 mm
Number of
KIT Code Installation Plates* Code
modules
FLOOR
Framework
EZDG 444 150x450 mm
EZD444MB
MB CM250058 250088
118
4 or 8 EZG844 250280 300x450 mm
353
EZG1644 250290 610x450 mm
408
Framework:
Coring:
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References
SELECTED REFERENCES
> Energy
> Service sector
> Heavy industry
China National Petroleum Corp. – China
Lukoil – Russia
Noble Drilling Services – Singapore
> Marine
> Infrastructure
> Processing industries
Samsung Electronics – South-Korea
MT MembraTec – Denmark
IN CABLOFIL ® THEY TRUST
Heathrow Airport, England, Terminal 5 (T5)
Manufacturing and distribution centre,
Nestlé Nespresso S.A.
venture.
managers love
which it can be
explains Jacques
electrotechnical
implementation at
the Nespresso site.
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Decision-making software
CABLOFIL ® has integrated 4 types of decision-making software to guide users throughout
every stage of the process, from design through the creation of the bills of material.
> CABLOSOFT: to recommend a solution
> CABLOCAD: to help design installations
> e-CATALOGUE: to put together a technical specification and generate a request for quotation
> 3D MODELLING: CABLOFIL installations can be modelled in 3D by Intergraph Software
CABLOCAD
AUTOCAD ® . It is a comprehensive resource containing all
e-CATALOGUE
CABLOSOFT
-
3D MODELLING
using interactive
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Specifications for power and data cable
supports
Welded steel wire cable trays shall comply with the description and performance levels
described below.
DESCRIPTION
Surface treatments for wire cable trays and related accessories
2
PERFORMANCE LEVELS
Wire cable trays:
th
Couplers:
Supports:
-
Earthing:
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Specifications for the firestop caulking of
cable pathways
After feeding electrical cables through a wall, the integrity of firestop walls must, without
exception, be restored using a firestop product that offers at least the same level of protection
as the original walls. Firestop products will comply with the description and performance
levels described below.
DESCRIPTION
connecting the earthing cable.
PERFORMANCE LEVELS
Firestop
SPECIFICATION
®
CABLOFIL ® .
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